fourche olhins .pdf



Nom original: fourche olhins.pdfTitre: 07282-04A.p65

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Owners Manual
Öhlins road & track front fork FG 43
Including:
Safety
Adjusters
Setting up
your fork
Changing
springs
Oil level
adjustment
Technical
information
Inspection &
maintenance
Service Tools

1

Safety signals
Important information concerning safety is
distinguished in this manual by the
following notations:

The Safety alert symbol means:
Caution! Your safety is involved.

WARNING!
Failure to follow warning instructions
could result in severe or fatal injury
to anyone working with, inspecting or
using the suspension, or to bystanders.

CAUTION!

Introduction
All of Öhlins advanced suspension products are
adapted to the brand and model. This means that
length, travel spring action and damping characteristics, are tested individually just for the
motorcycle that you have decided to fit with
Öhlins suspension.

Before installation
Öhlins Racing AB can not be held responsible
for any damage whatsoever to suspension or
vehicle, or injury to persons, if the instructions
for fitting and maintenance are not followed
exactly. Similarly, the warranty will become null
and void if the instructions are not adhered to.

2

2. Please study and make certain that you fully
understand all the mounting instructions and
the owner´s manuals before handling this
suspension kit. If you have any questions
regarding proper installation procedures, contact an Öhlins dealer or other qualified person.

NOTE

NOTE!

© Öhlins Racing AB.
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Öhlins Racing AB is prohibited.
Printed in Sweden.

1. Installing a suspension, that is not approved
by the vehicle manufacturer, may affect the
stability of your vehicle. Öhlins Racing AB cannot
be held responsible for any personal injury or
damage whatsoever that may occur after fitting
the suspension. Contact an Öhlins dealer or other
qualified person for advice.

3. The vehicle service manual must be referred
to when installing the Öhlins suspension.

Caution indicates that special precautions must be taken to avoid damage to the suspension.

This indicates information that is of
importance with regard to procedures.

WARNING!

Contents
Introduction ................................................... 3
Adjuster ......................................................... 4
Setting up your fork ....................................... 5
Setting the pre-load ....................................... 6
Changing springs .......................................... 7
Oil level adjustment ....................................... 8
Technical information ..................................... 9
Inspection & maintenance ........................... 10
Service tools ................................................ 11

Öhlins products are subject to continual improvement and development. Consequently, although
these instructions include the most up-to-date
information available at the time of printing, there
may be minor differences between your suspension and this manual. Please consult your Öhlins
dealer if you have any questions with regard to
the contents of the manual.

NOTE!
During storage and transportation, especially at
high ambient temperature, the oil and grease used
for assembling may run out inside the packing
and damage the expanded polystyrene packing
material. This is not unusual and is in no way detrimental to the suspension.

Öhlins front fork FG 43
The Öhlins front forks use a cartridge system for
damping. This gives a damping force which
depends on the speed of the piston in the
cartridge system.

Make sure your front forks are serviced regularly
and don’t use strong solvents such as brake
cleaner to clean the front forks. This will dry out
the seals and steel tubes and cause friction.

The combination of spring and air volume (oil level)
offers a possibility to adjust the characteristics of
the fork to suit different tracks and riders.

Regularly put a little Öhlins red grease (146-01)
regularly on the steel tube and work it in by pushing
the forks up and down.

For example a soft spring in combination with a
small air volume (high oil level) gives progressive
action of the front forks.
For better understanding, please refer to our oil
level chart, see page 8.
A telescopic front fork depends on smooth friction
free action.

3

Increase spring
pre-load
Reduce
spring
pre-load

3 mm allen key
Clockwise turn
closes = increase
rebound damping

Counter clockwise opens =
reduces compression damping

Clockwise closes =
increase compression
damping

14 mm wrench
Counter clockwise
turn opens =
reduced rebound
damping

3 mm allen key

Adjusters
Your öhlins front fork ø 43 is provided with the
following adjusters
• Spring pre-load
• Rebound damping adjuster
• Compression damping adjuster
Spring pre-load adjustment
Use 14 mm wrench to turn the upper adjustment
screw.

NOTE!
On some models adjustments are made with 12
mm wrench. These models has two larger nuts
below the adjustment screw and the top nut assy
.
Maximum adjustment range is 18 mm. One turn of
the adjustment screw will cause 1 mm change in
spring preload. Adjust so the front forks are lowered
25-30 mm from the top, unloaded position.

4

Rebound adjustment
Adjust the rebound rate on the adjustment screws
positioned at the top centre of the front forks.
Use a 3 mm allen key with a spherical head (use
tool 794-01).
Adjustment range from closed valve (clockwise)
to maximum open valve (counter-clockwise) is 20
“clicks”. See mounting instruction for recommended adjustment “clicks”, from closed position.

Compression adjustment
Adjust the compression rate on the lower part of
the front forks (compression valve). Use a 3 mm
allen key with spherical head (use tool 794-01).
Adjustment range from closed valve (clockwise)
to maximum open valve (counter-clockwise) is
20 “clicks”.
See mounting instruction for recommended
adjustment “clicks”, from closed position.

3. Static sag B-A

A

B

Setting up your fork

3

5

Here are some basic guidelines for setting up your
Öhlins front forks. However, you must remember
that the front forks are just one part of your
motorcycle and to get it to work properly, the whole
motorcycle has to be set up in conformance with
its manual.

Assemble the adjustment housing again and set
your initial preload of the spring by using a 12
mm or a 17 mm wrench until you get a “static
sag” of 25-30 mm.
Each turn gives 1 mm in preload. Maximum
preload is 15 mm.

1

4

Put your bike on a front stand so you can fit the
front forks.
Maximum torque on the bottom triple clamp and
steering damper bracket (if it is located on the
diameter of the outer tube) is 15-18 Nm.
Dismantle the front wheel and brakes.

The best way to check the “static sag” is to put
the bike on the ground in running condition.
Measure the distance between the bottom of
the outer tube to the fork bottom. Then lift the
front end of the bike, so the fork is fully extended.
Measure again. The difference between these two
figures is the “static sag”.

The “clicks” are a “bleed function”, separate for
rebound and compression damping. Rebound
adjustment is made on the top centre of the fork
and compression adjustment at the bottom part
of the fork.
You start to count from fully closed (clockwise)
and set it to the recommended “click” (use a 3
mm Allen key). For recommended start setting,
please refer to the mounting instruction.

2
Unscrew the adjustment housing on top of the
fork (use tool 797-04) on both upper tubes and
slide the fork up and down gently to make sure
everything works correctly.

5

F1
F2
R1

R2

Bike on a stand

F3
R3

Bike on the ground

Bike with rider on

Setting the spring pre-load
6

7

Pre-load on the spring/springs is very important,
because it affects the height of the motorcycle
and the fork angle. Consequently, handling characteristics can be changed, even negatively.
Proceed as follows (it will be much easier if done
by two persons):
1

Place the motorcycle on a stand.

2

Lift up the rear end to a fully
extended position.

3

Measure the distance, e.g. from the
lower edge of the rear mud guard or
from a point marked by a piece of
tape, immediately above the rear wheel
axle, to the wheel axle. (R1)

6

4

5

6

Make a similar measurement on the front
axle, e.g. from the bottom of the upper
fork crown to the front wheel axle.
The fork must also be fully extended. (F1)
Allow the motorcycle (without rider) to
apply load on the springs and repeat
the measuring procedure. (R2, F2)
Then take the same measurements
with the rider and equipment on the
motorcycle. It is important that the
rider has a correct riding posture,
so that the weight is balanced on the
front and rear wheel in the same way
as when riding. (R3, F3)

The measurements may not differ from the
following sizes:
Without rider:
Rear:
Front:

10-20 mm
15-30 mm

(R1-R2)
(F1-F2)

With rider:
Rear:
Front:

25-40 mm
35-50 mm

(R1-R3)
(F1-F3)

9

11

12

13

15
Wire with
a hook

Vice with
soft jaws

Adjustment
driver

Top nut
assy

Tool 797-04
Spring
Unloading
the spring

Top nut assy

Piston rod

Outer
fork leg

Changing springs
8

CAUTION!

Loosen the screws that hold the fork legs in the
upper triple clamps.

Do not damage the O-ring and do not drop the
flat key into the fork leg.
Carefully remove the adjustment housing.

9

13

Loosen the top nut assy (page 7) about two turns
(use tool 797-04).

Remove the adjustment driver, the pre-load tube
and spring.

10
11
Grip a fork leg in a vice. Use soft jaws.

The pre-load tube can be positioned above or
below the spring, depending on type of front fork.
Take note when dissasembling!

12
Unload the spring completely by turning the
adjustment screw anticlockwise. Use a 12 mm
or a 14 mm wrench.

15
Install the new spring, the adjustment driver and the
preload tube. Be careful to put all parts back in the
same position as when the fork was reassembled.

16
Reinstall the top nut assy.

CAUTION!

Remove the fork legs from the motorcycle.

Pre-load
tube

14
Pull out the piston rod as far as possible and turn
the compression adjustment screw fully clockwise.
This will keep the piston rod in top position, which
will make the continued assembly easier.

CAUTION!
Some models of top nut are equipped with a flat
key, that must be guided into the slot of the top
nut assy.

17
Fasten the adjustment housing in the fork leg.
Make sure that the fork leg is fully extended when
tightening the adjustment housing.

18
Install the fork legs on the motorcycle and adjust
the pre-load, compression and rebound according
to the instructions at page 4.
7

Air spring characteristics
Oil level

See:
Mounting
instructions
for specific
measurment

Oil level adjustment
Compared to conventional type of front forks, the
upside down front forks are very sensitive to
variations in oil level. Therefore, adjust the oil level
with special care.
A change in the fork oil level will not affect damping
force in the early stage of fork travel, but will have a
great effect in the later stage.
When the oil level is raised:
The air spring in the later half stage of travel is
stronger, and thus the front forks harder.
When the oil level is lowered:
The air spring in the later half stage of travel is
lessened, and thus the front forks are softer. The
oil level works most effectively at the end of the
fork travel. Air spring characteristics shown, refer
to a general card description to facilitate understanding of the difference when the oil level is
changed.
8

NOTE!
Adjust the oil level in mm according to the figure
with the fork fully compressed and with the spring
and the pre-load tube removed. For the right
recommended level, please see the mounting instruction.

Front spring kit

Technical information
Fork length:
See Mounting instructions.

Spring rate
See Mounting instructions.

Stroke:
See Mounting instructions.

Optional springs are available in following rates:

Free spring length:
See mounting instructions.
Rebound adjustment:
Basic setting 9-12 “clicks”.
Maximum open valve 20 “clicks”.
Compression adjustment:
Basic setting 6-16 “clicks”.
Maximum open valve 20 “clicks”.

04744-80
04744-85
04744-90
04744-95
04744-10

8.0 N/mm
8.5 N/mm
9.0 N/mm
9.5 N/mm
10.0 N/mm

Oil Level:
Please see Mounting instructions for the specific
front fork

CAUTION!
Use only Öhlins high performance front fork fluid
(1309-01).
Loctite glue:
542 on Fork bottom thread.
Tightening torque:
Triple clamp bolt 15-18 Nm.
Grease:
Öhlins front fork grease 00146-01 (red grease).

Spring preload adjustment:
0-15 mm (0-15 turns).

9

Inspection and maintenance
Clean the front fork externally with a soft detergent. Use compressed air. Be careful that all dirt
and debris is removed.
Keep the front fork clean and always spray it
with oil (QS 14, WD40 or CRC 5-56 or similar)
after washing the vehicle.

CAUTION!
Never use detergents that can damage the surfaces of the front fork. Use of thinner and brake
cleaner will dry the surfaces too much..

NOTE!
Make certain that your front fork is always filled with
Öhlins High Performance Front Fork Oil (1309-01).

NOTE!
Inspection points (see opposite page):
1. Check the front fork for leakage.
2. Check the front fork tubes for
external damages.
3. Fastening of caliper bracket and fender bracket.

Regular maintenance and inspection contribute
to the prevention of functional disturbances.
Recommended inspection and
maintenance intervals:
Normal use

4. Fastening to the vehicle.
Race track
Preventive maintenance and regular inspection
reduces the risk of functional disturbance. If there
is any need for additional service, please get in
touch with an authorised Öhlins service workshop.
There they have the necessary tools and knowhow for whatever you need.

Once a year
or every 5000 km
Every ten hours

Once every 2nd year (or 20 000 km), general:
Change front fork oil, use Öhlins front fork oil
(1309-01) only.

NOTE!
Discarded Öhlins products should be handled
over to an authorized work shop or distributor for
proper disposal.

10

Inspection points
4

Service tools
4701-01 Tool Kit

2

786-05
Clamp tool

4702-02
Cartridge tool

1

3

797-04
Top nut tool

787-03
Clamp tool

4705-01
Top nut holder

11

More info

The ultimate suspension site.
Find out everything about your suspension.
Download mounting instructions, manuals and brochures.
And a lot more.

Öhlins Racing AB, Box 722, S-194 27 Upplands Väsby, Sweden
Phone +46 8 590 025 00, Fax +46 8 590 025 80

Your Öhlins dealer:

12

07282-04A OM Front Fork Ø 43, Issued 05 12 20. Teknisk Illustration AB.

www.ohlins.com


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